Rail bond and method of making same



H. H. FEBREY RAIL BOND AND METHOD OF MAKING SAME Filed Sept. 5 1921 4 Sheets-Sheet l I. 2 J r 8 t o 3, a 5, a g S m4 l u G N Mm mm Ewfw A FMP 'Ee a HMS 0 0 Hmm I Am 1 D C N O B m u f M Nov. 4 y 1924- Winesses.'

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H. H. FEBREY RAIL BOND AND METHOD 0F MAKING SAME Filed Sept. 3 1921 4 Sheets-Sheet 5 jmvenr:

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H. H. FEBREY vRAIL BOND AND METHOD OF MAKING SAME Filed Sept. 5 )921 4 Shaken-Sheer?I 4 Patented Nov. 4, 1924.

UNITED STATES 1,513,805 PATENT oFFlcE;

HAROLD H. FEBRCEY, OEB` NEWARK, NEW JERSEY, ASSIGNO'R TO THE AMERICAN STEEL vAND WIRE COMPANY 0F NEW JERSEY, A CORPORATION OF NEW JERSEY.

RAIL BOND AND llVlIlEIJLIEIlOD OF MAKING SAME.

Application led September 3, 1921. Serial No.' 458,313.l

To all whom t may concern.'

Be it known thatI, HAROLD H. FEBREi, a citizen of the United States, and resident of Newark, in the county of 'Essex and State of New Jersey, have invented certain new and useful Improvements in Rail Bonds and Methods of Making Same, of which the following is a specification.

This invention relates to rail bonds, and while not limited thereto, more particularly relates to the manufacture of rail bonds having rigid terminals, formed of two dissimilar metals, on the ends of a flexible conductor, with the terminals permanently united to the ends of the conductor by a fusing or welding operation.

One object of my invention is the provision of an improved method of making rail bonds whereby the parts of the rail bond are secured one to another in providing the molten metal used to form the body portion of the rail bond terminals, and whereby the diiiiculties heretofore experienced in uniting or welding two dissimilar metals or metals differing in composition or electrical conductivity, such as steel and copper, are avoided and overcome.

Another object of my invention is the provision of a rail bond which is particularly adapted for use in applying rail bondsto a track rail by what is known as the metallic electrode arc welding process.

Another object of the invention is the provision in a rail bond of a conductor and terminals formed of cuprous or similar relatively soft metal and a rail engaging face ou the cuprous terminals formed of ferrous or similar relatively hard metal.

A. further object of this invention is to provide a rail bond having terminals of composite construction which are constructed with edges of restricted area to contact with. thc track rails prior to welding the bond terminals to the rails, so as to expose a maximum area of rail surface opposite the bond terminals for engagement by the contact metal employed in securing the rail bonds to the track rails.

Still further objectsof my invention consist in the provision of rail bonds having the novel constructions, arrangements, and' combination of parts shown in the drawings, to be described in detail hereinafter, and to be particularly pointed out in the appended claims.;

Referring now to the drawings, forming part of this specification, Figure l is an end elevation showing a track rail, y with one form of rail bond, (of T-head type), embodying my invention, as applied for use to the heads of the track rails. Figure 2 is a side elevation showing details in the construction of the rail bond of Figure l. Figure 8 lis a plan, and Figure 4 is an`end elevation showing details in the construction of the ends of the conductor of the rail bond of Figures l and 2, as formed prior to attaching the rail bond terminals thereto.

Figure 5 is a plan showing a preferred form of recessed mold used in fabricating the bond terminals and in uniting the parts of the bond terminals to each other and to the conductor ends, in accordance with the method forming part of this invention. Figure 6 is a sectional side elevation, on the line Vl-VI of Figure 5, showing further details in the construction o .f the mold of Figure 5, and the manner of supplying molten metal to the mold cavity in forming the bond terminals.

Figure 7 is a side elevation, partly in section, showing the rail bond conductor, with a terminal as built-up thereon in the mold of Figures 5 and 6, and Figure 8 is a sectional side elevation showing one arrangement of drop forging dies adapted for use in drop forging the rail bond terminals of Figure 7, to compact the metal in the bond terminals and finish the terminals to the desired shape and size.

Figure 9 is any end elevation showing a track rail, with a modified form of rail bond, (a long terminal single strand rail bond), constructed in accordance with this invention, as secured to the web of the track rail. Figure 10 is a perspective plan showingdetails in the construction of the vterminals of the rail bond of Figure 9. Figure 11 is a plan, and Figure 12 is a sectional end elevation, showing one form of recessed mold adaptedfor use in fabricating or building up the rail bond terminals of Figures 9 and 10, in accordance with my invention.

Figure 13 is an end elevation showing another modified form of rail bond, made in accordance with my invention, as secured to a track rail. Figure 14 is a side elevation showing details in the construction of the rail bond of Figure 13. Figure 1 5 is a plan showing one form of recessed mold adapted for use in forming the terminals of rail bonds like that shown in Figure '14, according to the method forming part of my invention.

Figure 16 is an end elevation showing a rail having another modified form of rail bond attached thereto, which embodies my invention and is made in accordance with the method formingpart of the invention. Figure 17 is a side elevation showing details in the construction of the rail bond of Figure 16. Figure 18 is a plan showing the construction of the rail bond terminal of the bond of Figures 16 and 17, as molded in accordance with my improved invention, and attached to the bond conductor preparatory to being drop forged to finished shape and size. Figure 191s an end elevation,

partly in section, of the rail bond terminal shown in Figure 18. Figure 2O is a sectional end elevationV showing details in the construction of the recessed mold used in fabricating the rail bond terminal of Figures 18 and 19.

In Figures 1 to 4 of the accompanying drawings, the numeral 2 designates the head of a track rail having the bond terminals secured thereto. The rail bondshown therein comprises a' flexible double strand conductor, 3 having a ferrule or sleeve 4, made of copper or like material, on the ends thereof. This ferrule 4 is used to temporarily.

secure together the ends of the strands forming the conductor, (see Figures 3 and 4),

. the sleeve laterbecoming fused and thereby merged with the body of the terminal 5 and end of the conductor 3. The terminal is provided with a rail contacting face 6, which is formed of a strip of steel or similar relatively hard ferrous metal approximating the electrical conductivity of the' rail head 2. t

As shown in Figure 1 the hard metal contact face 6 of the terminal is concave and has a bottom edge 7,.w,hich is adapted to i engage the side vsurface of the rail head 2 so 6 of the terminals will be flat, as in Figure as to form a pocket having a relatively wide bottom, the, result of shaping the pocket in this way being to facilitate the introduction and manipulation of the electrode used in welding,or supplyin the metal 8 used in welding the face of t e rail bond terminal to the rail and to increase the area o'f the rail surface in contact with the attaching metal 8. It will of course be understood that when desired, the rail contacting face 16, 'instead of curved in the manner shown 'in Figure 1.

In maklng rail bonds like that shown in Figures 1 and 2, a'mold 10, made of carbon,

is employed, (although a metal mold may be used), this mold having a recess or cavity 11 in the upper face thereof,vofsuitab1e preferablybeing formed of a non-metallic electrode'12. An'electric arc being established between the plate 6 and end of the conductor 3,' forming one terminal, and the non-metallic electrode 12 forming the other terminal, the adjoinin surfaces of the end 0f the conductor 3 an plate 6 will become heated and fused. A metal rod or pencil of suitable composition is then introduced into the electric arc and is fused thereby, the fused metal dropping into and gradually filling the mold cavity 11 and being united with or Welded to the fused surfaces of the end of the conductor 3 and the plate 6.

By filling the mold cavity 11 in this manner, a terminal having a body portion 5 and a hard metal face 6 with a rearwardly extending projection 4, is built up or formed,

the terminal made in this way being illustrated in Figure 7. The metal forming the body portion 5 of the terminal when made in 'this way is liable to be more or less porous and relativelyweak mechanically, and on account of itsrough appearance will appear unfinished, although in a condition for use.

The so formed terminal after being removed from its moldand cleaned, is heated, in the reducing flame of an oil'or other suitable furnace, to a forging temperature, or

temperature necessary to give the desired plasticity to the metal of the terminal. The

heated terminal is then drop forged within the cavity 13' of the top and bottom forging dies 14 and 15, (see Figure 8), and in this drop forging'operation the relatively soft metal forming the bodyl portion thereof is made more dense and homogeneous, so as to increase the strength and conductivity of the terminal, While it also is shaped to size and contourand given'- a uniform and nished appearance. -The outer surface ofthe platev 6 ofr the rail bond terminal may be made concave in this operation, as shown in Figure 1, or it may be made flat when de` sired. The shape of the cavities inthe drop forgin dies willbe :made of the contour desire .'f j

A.'t the completion of the dro for ing operation, the rail bond termina s wil be trimmed, to remove the flash or fin produced thereon in drop forging, and when the ste s as described above are repeated ,with t e other terminal of the rail bond, a completed article is made.

The modified form of rail bond shown in Figures 9 and 10 embodies the same general features as the bond of Figures 1 and 2, which has been described, except that in the long terminal bond of Figures 9 and 10, the hard metal rail engaging face 6a of the bond terminals 51L isv not concave and the conductor 3 is shown attached to the end of the terminals 5a (instead of to one side of the terminal, as in Figures `1 and 2). The rail bond of Figures 9 and 10 is adapted to be welded either to the flange or to the web of the track rail in bonding the rails, Figure 9 showing it secured to the rail web by means of the attachin'g metal 8a. Like parts in the rail bond of Figures 9 and 10 have the same numerals as in Figures 1 and 2, with the exponent a added thereto.

The terminals on the bonds of Figures 9 and 10 will be built up or fabricated and afterward drop forged in the same manner as has been described in connection with the rail bond of Figures 1 and 2. The end of the conductor 3a will be provided with a sleeve 4a and steel face 6a and the body portion 5a of the terminal will be built up in a.

vflaring surface to engage with the metal 8b used in securing the rail bond to the web of the track rails 2b. In molding or forming the terminals of the rail bond of Figures 13 and 14 right and left hand molds, constructed as shown `in Figure 15, will be employed. These molds 10b will have a suitable shaped cavity 11b therein and an L-shaped steel or other relatively hard metal face 6l will be inserted in the mold together with the end of the bond conductor 3b in the manner shown in Figure 15, and the metal added thereto in order to build up the body of the terminal will be supplied 1n the manner hereinbefore described in connection with the rail bond of Figures 1 and 2l.,

The double strand bond of Figures 13 and 14 will be built up, in a moldlike that shown inlFigure 15, in the same way as hereinbefore described. The ends of the strands forming the conductor?)b will be provided with sleeves 4b and the ends of the strands will be positioned within the cavity 11b of the mold 10b, together with a bent,

strip 6b of hard metal and the body, 5b of the L-shaped terminal will then be built up and welded to the terminal and strip 6b by fused f metal from a suitablerod or pencil. The so formed terminal will then be drop forged to size and finished shape.

In the rail bond illustrated in Figures 16 and 17, 18,v 19 and 20 (in which like parts have the same numerals applied thereto as in Figures 1 and 2, with the exponent c added), the ferrule or sleeve 4, to which the end of the iexible conductor 3 is secured, is formed by welding a short solid copper plug 4 to the body 5 of the terminal and at the same time the hard metal rail engaging face 6 is attached to the body of the terminal. The metal forming the body 5 of the terminal will be fused and added to the mold l()c in the same manner as has been described heretofore and after the terminals have been formed in the mold 10c in the manner shown in Figure 18, the plugs 4 are drilled to form a socket into which the end of the single strand terminal 3 is inserted. The terminal is then formed and put on the other end of the conductor 3. The terminals and connected ends of the bond conductor 3 are then heated and drop forged, this operation uniting the terminals to the conductor and shaping the terminals to size and the contour shown in Figures 17 and 18.

The many advantages of this invention will be apparent to those skilled in the art. Special attention is directed to the feature of having the terminals provided with only one steel face. thus allowing .the forging of the copper body.

bteel and copper will not flow equally in thedies when at an equal temperature, due to the difference in plasticity of these metals. However, when arranged as herein shown and described, with a steel face on but one side of the terminal, the steel will retain approximately its original position, while the iuovementbf the excess metal in the body of the terminal occurs .in the forgingr operation. i

It will, of course, be understood that` while the `drawings and specification show and describe rail bonds having both single and double strands forming the flexible conductor, any number of conductors, either flexible or rigid may be used as desired. It will also be understood that while I have described and shown certain forms of terminals with great particularity, that I do not wish to be limited to these exact forms since terminals of various shapes may readily be used, and different materials may be utilized in forming them.

Various other modifications may be made, as will be apparent to those skilled in the art, without departing from the spirit of my yinvention as defined in the appended claims.-

l. In the manufacture of rail bonds, the

steps consisting in securing a part of the bond terminal'and the end of the bond conductor within the cavity of a mold, and then adding molten 'metal to the mold cavity to thereby form the body of said 'terminal and unite said terminal part and conductor end to ysaid terminal body 2'. In the manufacture of rail bonds, the steps consisting in securing a part of the bond terminal and the end of the bond conductor within the cavity of a mold, heatingthe parts of the rail bond in said mold cavv ity, and then adding molten metal to the bond terminal and the end of the bond conductor within the cavity of a mold, heating mold cavity to thereby form the body of said terminal and unite said terminal part and conductor end to said terminalbody.

3. In the manufacture of rail bonds, the

v'steps consisting in securing a part of the boi-1d terminal and the end of the bond conductor withinvthe'cavity-of a mold, and then adding molten metal to the mold cavity to 4thereby form` the body of said terminal and unite said terminal part and conductor end to `said terminal body, and then heating and drop forging the terminal to size and finished shape. n

4,; -Inthemanufacture of rail bonds; the eps-consisting in securing a part of the the parts of the rail bond in said mold cavity, and then adding molten metal to the ,mold cavity to thereby form the body of `rsaid terminal and unite said terminal part` and conductor. end to lsaid terminal body,A

andthen heating and drop forging the terminal t 'size and finished shape.V

q The method of making rail bonds which consists in positioning the end of a metallic vconductor in a mold, positioning a strip of harder metal inthe mold in spaced relationpto said conductor end,'.filling the 4 intervening space vwith molten metal .and lthereby forming a terminal united to said co ductor end and having a contacting face of relatively hard metal, and then .heating and drop forging-the so formed terminal to size and shape.

metallic. conductor and a st ip of harder and dissimilar metal within a mold with the metal strip in spaced relation-to sald conductor, fusing the adjacentsurfaces of said .complete the rail bond.

'Off making" "mii bonds; which consists in positioning-the endv of a conductor end and said metal strip, filling the intervening space with molten metal and .A thereby forming a terminal bod having a contacting face of relatively har metal and united to saidconductor, and then heating and drop forging the so formed terminal to y compact and shape the metal of said terminal 1n saidforging step to final contour and size. 7. The method of making rail bonds which consists in positioning the end of the bond conductor in a mold cavity,- positioning a.

4strip of relatively harder metal in said mold A cavity in spaced relation to said conductor end, forming an electric arc between said conductor end, said plate and an electrode and thereby fusing the adjacent surfaces of said conductor end and said plate,`introducing a metal pencil into said arc, `and thereby `fusing 'the pencil and filling the space 1n said mold cavity with molten metal to unite said adjacent fused surfaces and `mold the terminal to shape, and then heating and drop forging said molded terminal to shape and size.

8. The method. of making rail bonds which consists in binding the ends of a bond conductor, shaping a terminal of relatively soft metal on each end of said conductor within a mold, securing a rail contacting face of relatively hard metal to said terminals in moldin the terminals, and then heating and forgmg the so formed terminals to further shape the terminals and -ing faces coacting with the rail to form av .pocket therebetween, and sald'railvengaging faces and the bod Aof said terminals being of Adissimilar meta s.- Y

Intestimonywhereof I have hereunto'set 105 'my hand. f l

HROLD H. FEBREY. i

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